Process for producing pearlescent plastic articles



2 Sheets-Sheet l E. M. MCELLIGOTT PROCESS FOR PRODUCING PEARLESCENT PLASTIC ARTICL Filed 0011. 4, 1949 Aug. 11, 1953 Z w o /H 1| w 11| J o0 Q f, w E 1 1 fn" M n 4. ||.Oil V V W -1- im w W Allg- 11, 1953 v E. M. MGELLIGOTT 2,548,098

PROCESS FOR PRODUCING PARLESCENT PLASTIC ARTICLES Filed Ooi. 4, i949 2 Sheets-Sheet 2 (Ittomegs Patented ug. klfl, 109573 PROCESS FOR PRODUCING PEARLESCENT PLASTIC ARTICLES Edward Michael McElligott, Detroit, Mich., assignor to Swedish Crucible Steel Company, Detroit, Mich., a corporation of Michigan Application October 4, 1949, Serial No. 119,434

5 Claims. l

'This invention relates to molding processes,

:and in particular to a process for molding pearl- .escent articles, such as picture frames, toilet .seats and the like.

One object of this invention is to provide a -rprocess of producing solid pearlescent plastic warticles which shall exhibit a variegated pearlyescent appearance in all parts of the article, even in cross-section, and wherein the completed :article will be permanently free from delaminaition or splitting apart in layers.

Another object is to provide a process of makfing pearlescent articles wherein a charge of a predetermined weight of the pearlescent plastic material is extruded from a mixing or extruding 1 machine into a form conveniently handled in 1a molding press and conveniently manipulated by theoperator with a minimum of operations.

Another object is to provide a process of pro- Another Objectis to provide a process of prof' ducing open-centered pearlescent plastic articles 1f, such'as picture frames, toilet seats and the like l 4wherein a charge of a predetermined weight of the mixture of plastics producing the pearlescent effect is extruded from a mixer in a ropelike mass, arranged in an open-centered formation on a convenient holder, or coiled directly r into the mold cavity of a molding press, twisted by the operator to break up regularity of pattern and prevent delamination, and molded while-in this twisted form.

Another object is to provide a process for molding open-centered pearlescent plastic articles wherein a mixing machine for the mixture of plastic materials which produce the pearlescent effect is provided with an extrusion orifice having a cross-section approximately corresponding to the cross-section of the mold cavity'and consequently of the article to be molded.

In the drawings:

Figure 1 is a top plan view of a plastic charge holder upon which a coil of rope-like plastic material is being extruded from a mixing or extruding machine;

Figure 2 is a side elevation of the apparatus shown in Figure l, showing the overlappingof the rope-like material to prevent seams;

Figure 3 is a top plan view of the lower mold showing the coil of plastic material in the mold cavity, after it has been twisted to prevent delamination and insure irregularity of pattern;

Figure 4 is a side elevation of the upper portion of a molding press, with the lower mold in central vertical section through Figure 3;

Figure 5 is a top plan View of a lower mold similar to Figure 3, but showing a modication of the process and apparatus wherein a single coil of the material is extruded in approximately the cross-section of the article to be molded;

Figure 6 is a vertical cross-section taken along the line 6 6 in Figure 5;

`Figure 7 vis a side elevation, partly in vcentral vertical section, 0i a modied molding press having a mixing or extruding device attached to the press and extruding the mixture of plastic materials directly into the mold cavity; and

Figure 8 is a perspective view of an opencenteredarticle produced by the process and apparatus of the present invention, such as a toilet seat.

General description the use of dangerously explosive solvents which gave off noxious fumes, thereby making the process uncomfortable and even hazardous to the operator. Other inventors endeavored to mold pearlescent plastic articles by injecting mixtures of variegated plastic materials into a plastic injection molding machine, but the articles rtherebyrproduced were found to be impermanent in that they sooner or later developed rdelamination or peeling off and cracking between the various layers of the different plastic materials. The present inventor originated a -process of producing solid pearlescent plastic articles which is described and claimed in his co-pending application Serial No. 34,644 led June ,23, 1948 for Process of Producing Pearlescent Articles now U. S. PatentNo. 2,516,065.

According to this process, a mixture of mutually incompatible plastics such as polystyrene4 resin and methylmethacrylate resins in powder form is placed in a mixing and extruding machine from which the mixture of materials is extruded onto a weighing scale until a predetermined quantity is accumulated, whereupon the rope-like stream of plastic material is severed. The material is accumulated in charges consisting of small piles or coils, these being placed at predetermined spaced locations around the mold cavity of the lower mold of the molding press. When the mold halves were closed, the material in being compressed was spread sidewise from each charge so that a continuous article was produced, with a minimum of motion or travel of the material.

The present process and apparatus are an improvement on the prior process in that the necessity for weighing out and accumulating the separate multiple charges of material is eliminated, and the possibility of delamination occurring at the boundaries or junctions between the streams of material coming from the different charges in the mold cavity is still further reduced. According to one form of the present invention, the mixture of mutually incompatible plastics producing the pearlescent efect is extruded from the nozzle of an extruding machine onto a holder of stainless steel or other suitable material in a shape roughly resembling a mans straw hat, the rope-like mass of extruded material being coiled around the upstanding central ange of the device a sufficient number of turns to produce the desired predetermined Weight of material which will exactly fill the mold with the minimum of flash remaining after molding. When the desired quantity has been thus accumulated in doughnut-like form, it is picked up by the operator, twisted at various points while preserving its open-centered form. and transferred in its twisted form to the mold cavity of a molding press. The mold is then closed, causing the strands of molding material to ll the mold cavity and produce the solid pearlescent article. The term solid is used herein to mean that the pearlescent effect is not merely a surface or skin eiect, but extends entirely through the article.

By this improved process of the present invention, the iinished article has a highly variegated appearance of pearlescence and at the same time is permanently free from delamination. The process is also substantially free from the necessity for estimates or guesswork on the part of the operator because a certain length of the plastic rope when coiled around the transfer device a specified number of turns gives a denite predetermined weight.

By a modiiication of the process and apparatus of the present invention (Figures and 6), a single coil or strand of the material is extruded from the mixing machine through a nozzle having a cross-section approximately corresponding to the cross-section of the article to be molded. This is either extruded directly onto the mold cavity or transferred thereto from a holder, the ends of the strand or coil being overlapped to prevent delamination at that point. By a still further modification of the process and apparatus (Figure 7), the plastic mixture is extruded directly into the die cavity from the nozzle of an extruder attached directly to the press and discharging directly into the die cavity, the cord or rope of material being preferably led around the die cavity by being grasped by tongs in the hands of the operator.

4, Detailed description Referring to the drawings in detail, Figures 1 to 4 inclusive show one form of process and apparatus for producing pearlescent plastic articles, according to the present invention. Figures 1 and 2 show an extruding machine, generally designated I0, depositing a coil I I of plastic material from a rope-like stream I2 from the nozzle I3 of the extruding machine I0 onto a charge holder, generally designated I4. The extruder I0 is of a conventional type well-known to engineers and its details are outside the scope of the present invention. For the purposes of the present disclosure, therefore, it is sufficient to state that the extruding machine I0 consists of a hollow casing I5 (Figure 2) having a central bore I6 in which a screw I'I operates and is rotated by a shaft I8 driven by a motor and reduction gearing (not shown). A heating jacket or chamber I9 surrounds the bore I6 Within the casing I5 and insures that the plastic mixture is kept sufiiciently hot to cause fusion. The nozzle I3 has an orice 20 of suitable size arranged at the end of a tapering nose portion 2l. The mixture of plastic materials, such as polystyrene and methylmethacrylate resins in powder form is placed in a hopper (not shown) leading into the opposite end of the bore I6 from the nose portion 2 I. The mixture of powdered plastic materials is thoroughly agitated by the screw Il and impelled forward at the same time, while it is heated by heat from the heating jacket I9. The latter may provide heat from steam or from an electric resistance winding, as is Well knownV in such machines.

The charge holder I 4 is preferably of stain-A less steel or other suitable material which is unaffected by the hot plastic materials being han-v dled. It is roughly in the shape of a mans straw hat with a brim-like supporting plate 22 and a crown-like upstanding annular portion or flange 23 rising therefrom.

roughly in the form of a hollow cylinder.

The molding press, generally designated 25, isof a conventional type having a head 26 con-1 nected by strain rods 2l to a bed (not shown).

Reciprocating vertically toward and away from.

the press head 2S is a platen 28 mounted on a plunger 29 which is reciprccable in the bore 3U of a hydraulic cylinder 3l.

eating therewith and connected to a source cf' suitable heating agent, such as steam. The lower' mold half 33 preferably contains the major portion of the mold cavity 39, which in this instance; is of approximately orbital shape with an island 45 rising in the middle thereof. The upper mold half 32 has a portion 4I of such an outline as to enter and t snugly within the mold cavity 39, and its lower surface is such as to iit snuglyagainst the upper surface of the island 4I), there-- by confining the material to the mold cavity 33. The latter, in the case of a toilet seat, has a side cavity 42 (Figure 3) with pockets 43 arranged to form upstanding lugs 44 (Figure 8) upon the In order to minimize its:` weight, the supporting plate 22 and upstanding` portion 23 are both formed of relatively thin sheet: material so that the upstanding portion 23 is.

By supplying pres-v sure fluid, such as oil, to the bottom of the cylinder 3I, beneath the lower end of the plunger rearward projection 45 or platform extending rearwardly from the seat portion 46 of the toilet seat, generally designated 41. The latter, of course, is of roughly angular or toroidal shape with an upper surface of arcuate cross-section and an open center 48.

In the operation of the apparatus shown in Figures 1 to 4 inclusive, and in carrying out the process of the present invention, the mixture of plastic materials in granulated form is placed in a conical tumbler or any other type of mixer and thoroughly mixed. The batch, as explained in my above-mentioned co-pending application, may consist of the following:

Per cent Methylmethacrylate resin, clear 60 Polystyrene resin, clear 35 Polystyrene resin, colored 100 After mixing, the batch is placed in the hopper of the extruder whence it descends to the bore IB thereof. As heat is applied to the chamber or jacket i9, either by steam or other heating agent or by an electrical resistance Winding therein, the heat is transferred through the inner wall of the casing I5 to the batch and fuses the materials together' so that it is extruded as a pastelike rope at a temperature of about 450 F.

As the rope-like strand I2 emerges from the nozzle I3 (Figures 1 and 2), it is permitted to deposit itself in a coil on the plate-like portion 22 of the holder I4, and is caused to wind around the upstanding flange 23 until the operator estimates that a suiiicient weight of material has been accumulated, whereupon he snips the strand I2 with a pair of scissors, cutting it off at the end 50. In Figure 2, it has been assumed that his estimate was incorrect and that an additional Weight of material was necessary to create the desired size of charge. The holder 22 may be placed on the platform of a weighing scale as described in my above-mentioned co-pending application, and weighed accurately, In depositing further material (Figure 2), the operator overlaps the end 5I with the end 50 so as to avoid a seam at this point. When the correct Weight is obtained, the strand I2 is again severed.

The operator now grasps the ring-like mass or coil of material on the holder I4 and lifts it off the holder, using gloves to insure cleanliness. The operator then twists the charge or coil 52 thus obtained at the location 53 (Figures 3 and 4) around the center line of the coil as an axis of twist in order to further insure irregularity of distribution and to further minimize the danger of delamination, producing the effect shown in Figure 3. He then places the thus twisted coil or charge 52 in the mold cavity 39, as shown in Figures 3 and 4. The number of turns making up the coil constituting the charge 52 on the holder I4 depends, of course, upon the size or the orice 2d in the nozzle I3 of the extruder I0. It is found convenient for one size of article and a certain size of orice to wind about three turns around the upstanding portion 23. It is preferred that the end of the strand shall terminate approximately diametrically opposite the beginning thereof so as to further minimize delamination.

Meanwhile, the upper and lower mold halves 32 and 33 have been suitably heated to approximately 325 to 350 F., such as by supplying steam to the heating jackets or chambers 36. Pressure fluid is then supplied to the bottom of the hydraulic cylinder 3| causing the plunger 29, platen 28 and lower mold half to rise, closing the mold halves and causing the coil-like charge -52 of material to spread out and iill the mold cavity. A pressure of approximately 3000 to 4000 pounds per square inch is employed, by using a molding pressure of approximately 250 tons.

When the mold halves 32 and 33 have com-f pletely closed, they are permitted to remain closed for three or four minutes so as to eject the flash or excess plastic material out of the mold, the amount of flash depending upon how closely the operator has estimated the charge to fill the mold cavity. Cooling water at approximately F. is then passed through the chambers 3B, cooling down the mold halves 32 and 33 and solidifying the contents. The iiuid is then released from the cylinder 3|, causing the platen 28 and mold half 33 to descend and open the mold. The molded article is then removed from the mold cavity 39 and the latter and the upper mold half 32 carefully cleaned so as to leave no trace of molding material or other foreign matter. The foregoing procedure is then repeated to mold subsequent articles 41. The article itself is found to exhibit a variegated pearlescent appearance and delamination does not occur even though the article is used over a long period of time.

M odified processes The modified process of Figures 5 and 6 employs the same or similar apparatus as that shown in Figures 1 to 4 inclusive, except that the extruder I0 is provided with a nozzle I3 having an orice 20 suiiiciently large in cross-section to approximate the size and shape of cross-section in the article to be molded. The charge 60 is extruded as before, but only a single turn is made (Figure 5) and the ends 6I and 62 are overlapped to prevent seams and a possible source of delamination. The charge 60 is either extruded directly into the mold cavity 39 or transferred thereto, and the pressing procedure is then carried out in the manner described. As the mold halves come together, the additional thickness of material provided bythe overlapping ends 6I and 62 spreads into the space 42 and pockets -43 at the rearward end of the mold cavity, filling this space and consequently providing the platform 45 and lugs 44 on the finished article 41 (Figure 8). In order to provide this result, it is of course desirable that the overlapped ends 6I and 62 be placed adjacent the space 42 so that the material will be required to move the least possible distance while it is filling the mold cavity.

The modification shown in Figure 7 employs a similar molding press to that shown in Figure 4, and similar parts are similarly designated with reference numerals. The modified apparatus is provided with an extruder 1I Which is attached directly to the platen 28 and which has its nozzle I3 discharging directly into an orifice 'I2 in the mold cavity 39. The extruder 1I is otherwise similar in construction to the extruder I0 of Figures 1 and 2. As a consequence, the mold charge is extruded directly into the mold cavity 39 and its extensions 42 and 43, the end of the strand or rope I2 being preferably led around the mold cavity 39 by grasping it with tongs and pulling it around the cavity 39. When a sui'licient amount of charge has been accumulated, the extruder 'Il is halted, and molding is then carried out in a manner similar to that described in connection with Figure 4.

What I claim is:

1. A process of molding pearlescent plastic articles from a pearlescent synthetic resin compound in a mold cavity, comprising reducing a compound composed of a plurality of mutuallyincompatible pearlescent-producing plastics to a plastic condition, extruding the plastic compound into a plastic rope, coiling said rope into an open-centered coil having vertically stacked multiple turns of approximately the size of the mold cavity, placing the extruded coil in the mold cavity, and compressing the coil to ll a prede- 1 termined portion of said cavity.

2. A process of molding pearlescent plastic articles from a pearlescent synthetic resin compound in a mold cavity, comprising reducing a compound composed of a plurality of mutually- 1 incompatible pearlescent-producing plastics to a plastic condition, extruding the plastic compound into a plastic rope, coiling said rope into an opencentered helical coil having vertically-stacked multiple turns of approximately the size of the mold cavity and having a plurality of turns, placing the extruded coil in the mold cavity, and compressing the coil to ll a predetermined portion of said cavity.

3. A process of molding pearlescent plastic articles from a pearlescent synthetic resin compound in a mold cavity, comprising reducing a compound composed of a plurality of mutuallyincompatible pearlescent-producing plastics to a plastic condition, extruding the plastic compound 3 into a plastic rope, coiling said rope into an opencentered coil of approximately the size of the mold cavity and having a plurality of turns, placing the extruded coil in the mold cavity, twisting portions of the coil relatively to other 3 portions thereof, and compressing the coil to ll a predetermined portion of said cavity.

4. A process of molding pearlescent plastic articles from a pearlescent synthetic resin compound in a mold cavity, comprising reducing a compound composed of a plurality of mutuallyincompatible pearlescent-producing plastics to a plastic condition, extruding the plastic compound into a plastic rope, coiling said rope into an opencentered coil having vertically-stacked multiple turns of approximately the size of the mold cavity and of a predetermined Weight, placing the extruded coil in the mold cavity, and compressing the coil to fill a predetermined portion of said cavity.

5. A process of molding pearlescent plastic articles from a pearlescent synthetic resin compound in a mold cavity, comprising reducing a compound composed of a plurality of mutuallyincompatible pearlescent-producing plastics to a. plastic condition, extruding the plastic compound into a coil composed of a plurality of strands, isaid coil being of approximately the size of the mold cavity, placing the extruded coil in the mold cavity, twisting certain strands of the coil relatively to other strands thereof around the center line of the coil as an axis of twist, and compressing the coil to ll a predetermined portion of said cavity.

EDWARD MICHAEL MCELLIGOTT.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 251,259 Lockwood Dec. 20, 1881 317,776 Heinrichs May 12, 1885 664,896 Robertson Jan. 1, 1901 1,370,024 Kempton Mar. 1, 1921 1,607,623 Higgins Nov. 23, 1926 1,631,663 Briggs June 7, 1927 1,944,464 Richardson Jan, 23, 1934 2,353,457 Goessling July 11, 1944 

